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Output Shaft: Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.
NOTE: General view of the output shaft. For additional information, refer to MANUAL TRANSAXLE .
NOTE: If there any new installation of bearings, shafts or the transaxle housings is necessary, the transaxle must be shimmed.
  1. Using the special tool, remove the taper roller bearing.
    Fig 1: Removing Taper Roller Bearing
    G03419691Courtesy of FORD MOTOR CO.
  2. Remove the reverse gear wheel.
    1. Reverse gear wheel
    2. Needle roller bearing
    3. Synchronizer ring
      Fig 2: Removing Reverse Gear Wheel
      G03419692Courtesy of FORD MOTOR CO.
  3. Remove the fifth/reverse gear synchronizer assembly.
    1. Snap ring
    2. Synchronizer assembly
      Fig 3: Removing Fifth/Reverse Gear Synchronizer Assembly
      G03419693Courtesy of FORD MOTOR CO.
  4. Remove the fifth gear wheel.
    1. Synchronizer ring
    2. Fifth gear wheel
    3. Bearing
      Fig 4: Removing Fifth Gear Wheel
      G03419694Courtesy of FORD MOTOR CO.
  5. Using the special tool, pull the taper roller bearing off the output shaft.
    Fig 5: Removing Taper Roller Bearing From Output Shaft
    G03419695Courtesy of FORD MOTOR CO.
    6. CAUTION: Note the marks on the output pinion for reinstallation. The output shaft and output pinion belong together and can only be installed new as a pair.
  6. Using the special tool, remove the output pinion and first gear.
    1. Remove the snap ring.
    2. Remove the output pinion and first gear wheel together.
      Fig 6: Removing Output Pinion And First Gear
      G03419696Courtesy of FORD MOTOR CO.
  7. Remove the double synchronizer.
    1. Needle roller bearing
    2. Inner synchronizer ring
    3. Synchronizer cone
    4. Outer synchronizer ring
      Fig 7: Removing Double Synchronizer
      G03419697Courtesy of FORD MOTOR CO.
  8. Remove the first/second gear synchronizer assembly.
    1. Snap ring
    2. Synchronizer assembly
      Fig 8: Removing First/Second Gear Synchronizer Assembly
      G03419698Courtesy of FORD MOTOR CO.
  9. Remove the double synchronizer together with the second gear wheel.
    1. Outer synchronizer ring
    2. Synchronizer cone
    3. Inner synchronizer ring
    4. Second gear wheel
    5. Needle roller bearing
      Fig 9: Removing Double Synchronizer With Second Gear Wheel
      G03419699Courtesy of FORD MOTOR CO.
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